WO2006012344A1 - Modified vegetable oil-based polyols - Google Patents
Modified vegetable oil-based polyols Download PDFInfo
- Publication number
- WO2006012344A1 WO2006012344A1 PCT/US2005/022580 US2005022580W WO2006012344A1 WO 2006012344 A1 WO2006012344 A1 WO 2006012344A1 US 2005022580 W US2005022580 W US 2005022580W WO 2006012344 A1 WO2006012344 A1 WO 2006012344A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- vegetable oil
- oligomeric
- polyol
- based polyol
- acid
- Prior art date
Links
- 229920005862 polyol Polymers 0.000 title claims abstract description 316
- 150000003077 polyols Chemical class 0.000 title claims abstract description 316
- 235000015112 vegetable and seed oil Nutrition 0.000 title claims abstract description 214
- 239000008158 vegetable oil Substances 0.000 title claims abstract description 214
- 238000000034 method Methods 0.000 claims abstract description 115
- 239000003054 catalyst Substances 0.000 claims abstract description 93
- 239000000203 mixture Substances 0.000 claims abstract description 91
- 235000014113 dietary fatty acids Nutrition 0.000 claims abstract description 16
- 239000000194 fatty acid Substances 0.000 claims abstract description 16
- 229930195729 fatty acid Natural products 0.000 claims abstract description 16
- 239000002253 acid Substances 0.000 claims description 55
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 38
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 35
- RILZRCJGXSFXNE-UHFFFAOYSA-N 2-[4-(trifluoromethoxy)phenyl]ethanol Chemical compound OCCC1=CC=C(OC(F)(F)F)C=C1 RILZRCJGXSFXNE-UHFFFAOYSA-N 0.000 claims description 23
- 235000013311 vegetables Nutrition 0.000 claims description 21
- 125000003700 epoxy group Chemical group 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 16
- 150000004665 fatty acids Chemical class 0.000 claims description 15
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 14
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 claims description 14
- -1 1,2-ethenediyl units Chemical group 0.000 claims description 12
- 125000002347 octyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 claims description 12
- 150000001875 compounds Chemical class 0.000 claims description 10
- 238000006735 epoxidation reaction Methods 0.000 claims description 10
- GVNVAWHJIKLAGL-UHFFFAOYSA-N 2-(cyclohexen-1-yl)cyclohexan-1-one Chemical compound O=C1CCCCC1C1=CCCCC1 GVNVAWHJIKLAGL-UHFFFAOYSA-N 0.000 claims description 8
- 101150065749 Churc1 gene Proteins 0.000 claims description 8
- 102100038239 Protein Churchill Human genes 0.000 claims description 8
- 238000002156 mixing Methods 0.000 claims description 7
- UFTFJSFQGQCHQW-UHFFFAOYSA-N triformin Chemical compound O=COCC(OC=O)COC=O UFTFJSFQGQCHQW-UHFFFAOYSA-N 0.000 claims description 7
- 239000003377 acid catalyst Substances 0.000 claims description 6
- 238000007142 ring opening reaction Methods 0.000 claims description 5
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 4
- 239000002841 Lewis acid Substances 0.000 claims description 3
- 239000004165 Methyl ester of fatty acids Substances 0.000 claims description 3
- 125000004183 alkoxy alkyl group Chemical group 0.000 claims description 3
- 125000003545 alkoxy group Chemical group 0.000 claims description 3
- 125000000278 alkyl amino alkyl group Chemical group 0.000 claims description 3
- 125000002877 alkyl aryl group Chemical group 0.000 claims description 3
- 235000019387 fatty acid methyl ester Nutrition 0.000 claims description 3
- 238000011065 in-situ storage Methods 0.000 claims description 3
- 150000007517 lewis acids Chemical class 0.000 claims description 3
- 238000006116 polymerization reaction Methods 0.000 claims description 3
- 125000000217 alkyl group Chemical group 0.000 claims description 2
- 150000001735 carboxylic acids Chemical class 0.000 claims description 2
- 150000007522 mineralic acids Chemical class 0.000 claims description 2
- 125000000325 methylidene group Chemical group [H]C([H])=* 0.000 claims 27
- 238000007037 hydroformylation reaction Methods 0.000 abstract description 34
- 239000003921 oil Substances 0.000 abstract description 28
- 235000019198 oils Nutrition 0.000 abstract description 28
- 238000005984 hydrogenation reaction Methods 0.000 abstract description 22
- 238000006243 chemical reaction Methods 0.000 description 75
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 72
- 125000001570 methylene group Chemical group [H]C([H])([*:1])[*:2] 0.000 description 71
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 68
- 235000012424 soybean oil Nutrition 0.000 description 54
- 239000003549 soybean oil Substances 0.000 description 54
- 239000011541 reaction mixture Substances 0.000 description 39
- 230000008569 process Effects 0.000 description 34
- 239000003456 ion exchange resin Substances 0.000 description 32
- 229920003303 ion-exchange polymer Polymers 0.000 description 32
- 239000000376 reactant Substances 0.000 description 31
- 238000003756 stirring Methods 0.000 description 31
- NWUYHJFMYQTDRP-UHFFFAOYSA-N 1,2-bis(ethenyl)benzene;1-ethenyl-2-ethylbenzene;styrene Chemical compound C=CC1=CC=CC=C1.CCC1=CC=CC=C1C=C.C=CC1=CC=CC=C1C=C NWUYHJFMYQTDRP-UHFFFAOYSA-N 0.000 description 28
- 239000000047 product Substances 0.000 description 28
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 27
- 239000002904 solvent Substances 0.000 description 24
- 229910052751 metal Inorganic materials 0.000 description 22
- 239000002184 metal Substances 0.000 description 22
- 230000035484 reaction time Effects 0.000 description 22
- ZCYVEMRRCGMTRW-UHFFFAOYSA-N 7553-56-2 Chemical compound [I] ZCYVEMRRCGMTRW-UHFFFAOYSA-N 0.000 description 21
- 239000011630 iodine Substances 0.000 description 21
- 229910052740 iodine Inorganic materials 0.000 description 21
- 230000003472 neutralizing effect Effects 0.000 description 20
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 19
- 239000003795 chemical substances by application Substances 0.000 description 17
- 238000010992 reflux Methods 0.000 description 17
- 239000007787 solid Substances 0.000 description 15
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 14
- 229910052739 hydrogen Inorganic materials 0.000 description 13
- 239000001257 hydrogen Substances 0.000 description 13
- 239000004615 ingredient Substances 0.000 description 13
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 12
- 238000001914 filtration Methods 0.000 description 12
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical class CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 12
- 239000011347 resin Substances 0.000 description 12
- 229920005989 resin Polymers 0.000 description 12
- 238000004458 analytical method Methods 0.000 description 11
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 11
- 239000007789 gas Substances 0.000 description 11
- 239000007788 liquid Substances 0.000 description 11
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 10
- 150000007513 acids Chemical class 0.000 description 10
- 239000007795 chemical reaction product Substances 0.000 description 10
- 229910017052 cobalt Inorganic materials 0.000 description 10
- 239000010941 cobalt Substances 0.000 description 10
- 239000000543 intermediate Substances 0.000 description 10
- 239000000463 material Substances 0.000 description 10
- 150000004965 peroxy acids Chemical class 0.000 description 10
- 239000000843 powder Substances 0.000 description 10
- 238000002360 preparation method Methods 0.000 description 10
- 238000009835 boiling Methods 0.000 description 9
- 239000000706 filtrate Substances 0.000 description 9
- 238000006386 neutralization reaction Methods 0.000 description 9
- 239000000126 substance Substances 0.000 description 9
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 8
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 8
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 8
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical class CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 8
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 8
- 230000008901 benefit Effects 0.000 description 8
- 239000000243 solution Substances 0.000 description 8
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 7
- 239000004593 Epoxy Substances 0.000 description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 7
- 230000002378 acidificating effect Effects 0.000 description 7
- 239000012153 distilled water Substances 0.000 description 7
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid group Chemical group C(CCCCCCC\C=C/CCCCCCCC)(=O)O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 7
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 6
- ATRRKUHOCOJYRX-UHFFFAOYSA-N Ammonium bicarbonate Chemical compound [NH4+].OC([O-])=O ATRRKUHOCOJYRX-UHFFFAOYSA-N 0.000 description 6
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 6
- 239000001099 ammonium carbonate Substances 0.000 description 6
- 235000012501 ammonium carbonate Nutrition 0.000 description 6
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 6
- 239000000178 monomer Substances 0.000 description 6
- 239000001301 oxygen Substances 0.000 description 6
- 229910052760 oxygen Inorganic materials 0.000 description 6
- 238000000926 separation method Methods 0.000 description 6
- 238000005292 vacuum distillation Methods 0.000 description 6
- 238000000214 vapour pressure osmometry Methods 0.000 description 6
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 5
- 229910004039 HBF4 Inorganic materials 0.000 description 5
- 230000004913 activation Effects 0.000 description 5
- 150000001298 alcohols Chemical class 0.000 description 5
- 229910052799 carbon Inorganic materials 0.000 description 5
- 239000006229 carbon black Substances 0.000 description 5
- 229910002091 carbon monoxide Inorganic materials 0.000 description 5
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 5
- 239000000539 dimer Substances 0.000 description 5
- 238000002474 experimental method Methods 0.000 description 5
- 239000011521 glass Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 239000003208 petroleum Substances 0.000 description 5
- 239000002002 slurry Substances 0.000 description 5
- 239000013638 trimer Substances 0.000 description 5
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 4
- HEDRZPFGACZZDS-UHFFFAOYSA-N Chloroform Chemical compound ClC(Cl)Cl HEDRZPFGACZZDS-UHFFFAOYSA-N 0.000 description 4
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 4
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 4
- KFSLWBXXFJQRDL-UHFFFAOYSA-N Peracetic acid Chemical compound CC(=O)OO KFSLWBXXFJQRDL-UHFFFAOYSA-N 0.000 description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 4
- 229910000019 calcium carbonate Inorganic materials 0.000 description 4
- 239000012043 crude product Substances 0.000 description 4
- 238000009472 formulation Methods 0.000 description 4
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- 238000006384 oligomerization reaction Methods 0.000 description 4
- 238000000746 purification Methods 0.000 description 4
- 229920006395 saturated elastomer Polymers 0.000 description 4
- 239000007858 starting material Substances 0.000 description 4
- 239000010902 straw Substances 0.000 description 4
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 3
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 3
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 3
- NLZUEZXRPGMBCV-UHFFFAOYSA-N Butylhydroxytoluene Chemical compound CC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 NLZUEZXRPGMBCV-UHFFFAOYSA-N 0.000 description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 3
- 239000005642 Oleic acid Substances 0.000 description 3
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 3
- 235000019486 Sunflower oil Nutrition 0.000 description 3
- 238000010521 absorption reaction Methods 0.000 description 3
- 229960000583 acetic acid Drugs 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 235000010354 butylated hydroxytoluene Nutrition 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 150000002431 hydrogen Chemical class 0.000 description 3
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 3
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 3
- 238000011027 product recovery Methods 0.000 description 3
- 238000010926 purge Methods 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
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- 239000002600 sunflower oil Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 238000005406 washing Methods 0.000 description 3
- 238000010626 work up procedure Methods 0.000 description 3
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- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 2
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- OFBQJSOFQDEBGM-UHFFFAOYSA-N Pentane Chemical compound CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 2
- SCKXCAADGDQQCS-UHFFFAOYSA-N Performic acid Chemical compound OOC=O SCKXCAADGDQQCS-UHFFFAOYSA-N 0.000 description 2
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- 235000019485 Safflower oil Nutrition 0.000 description 2
- UIIMBOGNXHQVGW-DEQYMQKBSA-M Sodium bicarbonate-14C Chemical compound [Na+].O[14C]([O-])=O UIIMBOGNXHQVGW-DEQYMQKBSA-M 0.000 description 2
- 235000021355 Stearic acid Nutrition 0.000 description 2
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 description 2
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- 241000364021 Tulsa Species 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 235000020661 alpha-linolenic acid Nutrition 0.000 description 2
- DTOSIQBPPRVQHS-PDBXOOCHSA-N alpha-linolenic acid Chemical compound CC\C=C/C\C=C/C\C=C/CCCCCCCC(O)=O DTOSIQBPPRVQHS-PDBXOOCHSA-N 0.000 description 2
- 150000001412 amines Chemical class 0.000 description 2
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- 239000000010 aprotic solvent Substances 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- YZXBAPSDXZZRGB-DOFZRALJSA-N arachidonic acid Chemical compound CCCCC\C=C/C\C=C/C\C=C/C\C=C/CCCC(O)=O YZXBAPSDXZZRGB-DOFZRALJSA-N 0.000 description 2
- 239000002585 base Substances 0.000 description 2
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- GDVKFRBCXAPAQJ-UHFFFAOYSA-A dialuminum;hexamagnesium;carbonate;hexadecahydroxide Chemical compound [OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Al+3].[Al+3].[O-]C([O-])=O GDVKFRBCXAPAQJ-UHFFFAOYSA-A 0.000 description 2
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- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
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- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 2
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- 241000894007 species Species 0.000 description 2
- 238000007655 standard test method Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert‐butyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 2
- VZGDMQKNWNREIO-UHFFFAOYSA-N tetrachloromethane Chemical compound ClC(Cl)(Cl)Cl VZGDMQKNWNREIO-UHFFFAOYSA-N 0.000 description 2
- 229910052723 transition metal Inorganic materials 0.000 description 2
- 150000003624 transition metals Chemical class 0.000 description 2
- RIOQSEWOXXDEQQ-UHFFFAOYSA-N triphenylphosphine Chemical compound C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1 RIOQSEWOXXDEQQ-UHFFFAOYSA-N 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 239000008096 xylene Substances 0.000 description 2
- OYHQOLUKZRVURQ-NTGFUMLPSA-N (9Z,12Z)-9,10,12,13-tetratritiooctadeca-9,12-dienoic acid Chemical compound C(CCCCCCC\C(=C(/C\C(=C(/CCCCC)\[3H])\[3H])\[3H])\[3H])(=O)O OYHQOLUKZRVURQ-NTGFUMLPSA-N 0.000 description 1
- XYPISWUKQGWYGX-UHFFFAOYSA-N 2,2,2-trifluoroethaneperoxoic acid Chemical compound OOC(=O)C(F)(F)F XYPISWUKQGWYGX-UHFFFAOYSA-N 0.000 description 1
- LBLYYCQCTBFVLH-UHFFFAOYSA-N 2-Methylbenzenesulfonic acid Chemical compound CC1=CC=CC=C1S(O)(=O)=O LBLYYCQCTBFVLH-UHFFFAOYSA-N 0.000 description 1
- BVXMSQWCZAGNTO-UHFFFAOYSA-N 3,5-dinitrobenzenecarboperoxoic acid Chemical compound OOC(=O)C1=CC([N+]([O-])=O)=CC([N+]([O-])=O)=C1 BVXMSQWCZAGNTO-UHFFFAOYSA-N 0.000 description 1
- NHQDETIJWKXCTC-UHFFFAOYSA-N 3-chloroperbenzoic acid Chemical compound OOC(=O)C1=CC=CC(Cl)=C1 NHQDETIJWKXCTC-UHFFFAOYSA-N 0.000 description 1
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- 239000005711 Benzoic acid Substances 0.000 description 1
- 235000003901 Crambe Nutrition 0.000 description 1
- 241000220246 Crambe <angiosperm> Species 0.000 description 1
- 238000005033 Fourier transform infrared spectroscopy Methods 0.000 description 1
- 235000010469 Glycine max Nutrition 0.000 description 1
- OYHQOLUKZRVURQ-HZJYTTRNSA-N Linoleic acid Chemical compound CCCCC\C=C/C\C=C/CCCCCCCC(O)=O OYHQOLUKZRVURQ-HZJYTTRNSA-N 0.000 description 1
- 239000004839 Moisture curing adhesive Substances 0.000 description 1
- 235000019482 Palm oil Nutrition 0.000 description 1
- 239000007868 Raney catalyst Substances 0.000 description 1
- 229910000564 Raney nickel Inorganic materials 0.000 description 1
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 229940114079 arachidonic acid Drugs 0.000 description 1
- 235000021342 arachidonic acid Nutrition 0.000 description 1
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 1
- 235000010233 benzoic acid Nutrition 0.000 description 1
- WXSHFZLFJRYRKN-UHFFFAOYSA-N benzyl hydroxy carbonate Chemical compound OOC(=O)OCC1=CC=CC=C1 WXSHFZLFJRYRKN-UHFFFAOYSA-N 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- GGRQQHADVSXBQN-FGSKAQBVSA-N carbon monoxide;(z)-4-hydroxypent-3-en-2-one;rhodium Chemical compound [Rh].[O+]#[C-].[O+]#[C-].C\C(O)=C\C(C)=O GGRQQHADVSXBQN-FGSKAQBVSA-N 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 235000005687 corn oil Nutrition 0.000 description 1
- 239000002285 corn oil Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 235000012343 cottonseed oil Nutrition 0.000 description 1
- 239000002385 cottonseed oil Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- YQHLDYVWEZKEOX-UHFFFAOYSA-N cumene hydroperoxide Chemical compound OOC(C)(C)C1=CC=CC=C1 YQHLDYVWEZKEOX-UHFFFAOYSA-N 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- WLGSIWNFEGRXDF-UHFFFAOYSA-N dodecanoic acid Chemical compound CCCCCCCCCCCC(O)=O.CCCCCCCCCCCC(O)=O WLGSIWNFEGRXDF-UHFFFAOYSA-N 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 235000021323 fish oil Nutrition 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 125000002485 formyl group Chemical class [H]C(*)=O 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- KYYWBEYKBLQSFW-UHFFFAOYSA-N hexadecanoic acid Chemical compound CCCCCCCCCCCCCCCC(O)=O.CCCCCCCCCCCCCCCC(O)=O KYYWBEYKBLQSFW-UHFFFAOYSA-N 0.000 description 1
- 239000008172 hydrogenated vegetable oil Substances 0.000 description 1
- 150000002432 hydroperoxides Chemical class 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- NHXTZGXYQYMODD-UHFFFAOYSA-N icosanoic acid Chemical compound CCCCCCCCCCCCCCCCCCCC(O)=O.CCCCCCCCCCCCCCCCCCCC(O)=O NHXTZGXYQYMODD-UHFFFAOYSA-N 0.000 description 1
- 239000012442 inert solvent Substances 0.000 description 1
- 150000002484 inorganic compounds Chemical class 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000012948 isocyanate Substances 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- 239000000787 lecithin Substances 0.000 description 1
- 235000010445 lecithin Nutrition 0.000 description 1
- 235000020778 linoleic acid Nutrition 0.000 description 1
- OYHQOLUKZRVURQ-IXWMQOLASA-N linoleic acid Natural products CCCCC\C=C/C\C=C\CCCCCCCC(O)=O OYHQOLUKZRVURQ-IXWMQOLASA-N 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 239000012038 nucleophile Substances 0.000 description 1
- 230000000269 nucleophilic effect Effects 0.000 description 1
- 235000021313 oleic acid Nutrition 0.000 description 1
- 239000004006 olive oil Substances 0.000 description 1
- 235000008390 olive oil Nutrition 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 229910052762 osmium Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 239000002540 palm oil Substances 0.000 description 1
- 230000002572 peristaltic effect Effects 0.000 description 1
- 239000010773 plant oil Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920005903 polyol mixture Polymers 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000013557 residual solvent Substances 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 235000003441 saturated fatty acids Nutrition 0.000 description 1
- 150000004671 saturated fatty acids Chemical class 0.000 description 1
- 239000000565 sealant Substances 0.000 description 1
- 239000008159 sesame oil Substances 0.000 description 1
- 235000011803 sesame oil Nutrition 0.000 description 1
- 238000007086 side reaction Methods 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 125000005415 substituted alkoxy group Chemical group 0.000 description 1
- CBYCSRICVDBHMZ-UHFFFAOYSA-N tetracosanoic acid Chemical compound CCCCCCCCCCCCCCCCCCCCCCCC(O)=O.CCCCCCCCCCCCCCCCCCCCCCCC(O)=O CBYCSRICVDBHMZ-UHFFFAOYSA-N 0.000 description 1
- ZTUXEFFFLOVXQE-UHFFFAOYSA-N tetradecanoic acid Chemical compound CCCCCCCCCCCCCC(O)=O.CCCCCCCCCCCCCC(O)=O ZTUXEFFFLOVXQE-UHFFFAOYSA-N 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 150000003626 triacylglycerols Chemical class 0.000 description 1
- 125000005457 triglyceride group Chemical group 0.000 description 1
- 238000003828 vacuum filtration Methods 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/30—Low-molecular-weight compounds
- C08G18/36—Hydroxylated esters of higher fatty acids
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07D—HETEROCYCLIC COMPOUNDS
- C07D303/00—Compounds containing three-membered rings having one oxygen atom as the only ring hetero atom
- C07D303/02—Compounds containing oxirane rings
- C07D303/38—Compounds containing oxirane rings with hydrocarbon radicals, substituted by carbon atoms having three bonds to hetero atoms with at the most one bond to halogen, e.g. ester or nitrile radicals
- C07D303/40—Compounds containing oxirane rings with hydrocarbon radicals, substituted by carbon atoms having three bonds to hetero atoms with at the most one bond to halogen, e.g. ester or nitrile radicals by ester radicals
- C07D303/42—Acyclic compounds having a chain of seven or more carbon atoms, e.g. epoxidised fats
Definitions
- This invention relates to vegetable oil-based polyols.
- Polyols are generally produced from petroleum. Polyols are useful in a variety of applications, as polyols may be used in coatings, adhesives, sealants, elastomers, resins and foams. Polyols may be used in a wide variety of fields including the textile, plastic, medical, chemical, manufacturing, and cosmetic industries.
- non-petroleum based polyols include those described by Petrovic et al. in U.S. Patents 6,107,433, 6,433,121, 6,573,354, and 6,686,435. Another example is described in Kurth, U.S. Patent Number 6,180,686.
- Modified vegetable oil-based polyols are described that include unreacted double bonds. Additionally, partially epoxidized vegetable oils, which also include unreacted double bonds, are described. In one aspect, a method of making an unsaturated modified vegetable oil- based polyol is described, including reacting a partially epoxidized vegetable oil, a proton donor, and fluoroboric acid to form the unsaturated modified vegetable oil-based polyol.
- the method also includes neutralizing the unsaturated modified vegetable oil-based polyol.
- neutralizing includes the addition Of Ca(OH) 2 , CaO, hydrotalcite, ammonium carbonate, diethanolamine, triethanolamine, or alkali or alkaline earth hydroxides.
- the method also includes reacting a vegetable oil with a peroxyacid under reaction conditions that epoxidize less than 100% of the double bonds of the vegetable oil available for reaction to form the partially epoxidized vegetable oil.
- the reactions are performed without purification between the reactions.
- the proton donor includes alcohol.
- the alcohol includes a polyol or includes methanol.
- the proton donor includes water. The reaction may proceed for less than about 5 hours, less than about 3 hours, proceeds for about 60 minutes or less, or may proceed for about 20 to about 40 minutes.
- the unsaturated modified vegetable oil-based polyol has a substantially preserved triglyceride structure.
- the unsaturated modified vegetable oil-based polyol has a viscosity measured at 25 0 C from about 0.05 Pa. s to about 12.0 Pa. s.
- the unsaturated modified vegetable oil-based polyol may have a hydroxyl number from about 20 to about 300 mg KOH/g polyol.
- the unsaturated modified vegetable oil-based polyol may have a functionality from about 1.0 to about 6.0.
- the unsaturated modified vegetable oil-based polyol may have an iodine value from about 5 to about 120.
- the unsaturated modified vegetable-oil based polyol may have a Gardner color value of less than about 3.0.
- the unsaturated modified vegetable-oil based polyol may have a Gardner color value of less than about 2.5.
- the fiuoroboric acid is self-regulating.
- the unsaturated modified vegetable oil-based polyol may have an epoxy oxygen content (EOC) from about 0% to about 3%.
- the unsaturated modified vegetable oil-based polyol may have an epoxy oxygen content (EOC) from about 0% to about 0.1%.
- a method of preparing a polyol including combining a partially epoxidized vegetable oil, alcohol, and a catalytic amount of acid to form the unsaturated modified vegetable oil-based polyol is described.
- water may be present.
- the acid is fiuoroboric acid.
- a method of making an oligomeric modified vegetable oil-based polyol including reacting a mixture including an epoxidized vegetable oil and a ring opener to form an oligomeric modified vegetable oil-based polyol, wherein the oligomeric modified vegetable oil-based polyol comprises at least about 20% oligomers, and a viscosity at 25°C of less than about 8 Pa.s.
- the mixture also includes an acid.
- the acid includes fluoroboric acid.
- the fluoroboric acid is self-regulating.
- the acid includes carboxylic acids, Lewis acids, and Bronsted-Lowry inorganic acids.
- the oligomeric modified vegetable oil-based polyol includes at least about 40% oligomers. In some embodiments, the oligomeric modified vegetable oil-based polyol includes at least about 50% oligomers.
- the ring opener includes alcohol. In some cases, the alcohol includes a branched alcohol. In other cases, the alcohol includes a linear alcohol. In some embodiments, the ring opener includes a vegetable-oil based polyol. In some embodiments, the ring opener includes a proton donor. In some embodiments, the ring opener includes hydroxyl groups, and wherein the ratio of hydroxyl groups present in the ring opener to epoxy groups present in the epoxidized vegetable oil is from about 0.1 to about 1.0.
- the method also includes blending petrochemical- based polyols with the epoxidized vegetable oil and the ring opener so that said petrochemical-based polyols also undergo the polymerization reaction.
- the epoxidized vegetable oil includes essentially full epoxidation of all unsaturated groups present in the vegetable oil. In others, the epoxidized vegetable oil includes less than about 90% epoxidation of all unsaturated groups present in the vegetable oil. In others, the epoxidized vegetable oil includes less than about 80% epoxidation of all unsaturated groups present in the vegetable oil. In some cases, the oligomeric modified vegetable oil-based polyol has residual epoxide functionality. In other cases, the oligomeric modified vegetable oil-based polyol has residual olefmic functionality. In other cases, the oligomeric modified vegetable oil-based polyol has residual epoxide functionality and has residual olefmic functionality.
- the oligomeric modified vegetable oil-based polyol may have a functionality from about 1.0 to about 6.0.
- the oligomeric modified vegetable oil-based polyol may have a hydroxyl number from about 20 to about 300 mg 22580
- the oligomeric modified vegetable oil-based polyol may have a number average molecular weight from about 1,200 to about 8,000.
- the oligomeric modified vegetable oil-based polyol may have a weight average molecular weight from about 1500 to about 50,000.
- the epoxidized vegetable oil is formed in situ from a vegetable oil in the presence of an acid.
- the method includes ring-opening the epoxidized vegetable oil using an alcohol and an acid catalyst, and reacting an epoxidized vegetable oil with the ring-opened epoxidized vegetable oil.
- a method of making an oligomeric modified vegetable oil-based polyol including reacting a mixture comprising an epoxidized vegetable oil, fluoroboric acid, and a ring opener to form an oligomeric modified vegetable oil-based polyol.
- a method of making an oligomeric modified vegetable oil-based polyol including reacting a mixture comprising an epoxidized vegetable oil and a ring opener to form an oligomeric modified vegetable oil-based polyol, wherein the oligomeric modified vegetable oil-based polyol comprises at least about 40% oligomers.
- a method of making an oligomeric modified vegetable oil-based polyol including reacting a mixture comprising an epoxidized vegetable oil, an acid catalyst, and a polyol to form an oligomeric modified vegetable oil-based polyol.
- methods of making oligomeric modified vegetable oil-based polyols including cationically polymerizing an epoxidized vegetable oil in the presence of an acid catalyst, or reacting a polyol with an epoxidized vegetable oil, or combining a modified vegetable oil-based polyol, a catalytic amount of acid, and an epoxidized vegetable oil to form the oligomeric modified vegetable oil-based polyol.
- a method of making a polyol including reacting an epoxidized vegetable oil with a ring opener to form a modified vegetable oil-based polyol, wherein the ring opener is a reduced hydroformylated compound.
- the reduced hydroformylated compound includes a reduced hydroformylated vegetable oil- 005/022580
- the reduced hydroformylated compound includes reduced hydroformylated methyl esters of fatty acids.
- a method of making a polyol including hydroformylating a vegetable oil to form an aldehydic intermediate in the presence of a catalyst, and hydrogenating the aldehydic intermediate to form a polyol in the presence of the catalyst and a support.
- the method also includes activating a catalyst comprising metal on a support to form a catalyst comprising a metal carbonyl.
- the catalyst on a support is in an organic media.
- the organic media may be recovered after the hydrogenation step.
- the organic media may be recovered by vacuum stripping.
- the organic media includes aromatics, hydrocarbons, or combinations thereof.
- the organic media includes hexanes, heptanes, benzene, toluene, acetone, chloroform, methanol, ethanol, isopropanol, butanol, ethyl acetate, and combinations thereof.
- the catalyst, the support, and an organic media are recovered after the hydrogenation step. Some embodiments may include mixing the recovered catalyst, support and organic media together under conditions to re-activate the catalyst.
- the re-activated catalyst may be used in hydroformylation and hydrogenation reactions.
- the catalyst may include a metal, or a metal carbonyl.
- the metal comprises a transition metal within Group VIIIB of the periodic chart.
- the metal carbonyl includes cobalt carbonyl.
- the support includes carbon black.
- the support includes carbon black, alumina, silica, TiO 2 , MgO, ZnO, CaCO 3 , CaSO 4 , MgSO 4 , or combinations thereof.
- the hydroformylation step takes place at a pressure of about 1000-5000 psig of gas and at a temperature from about 100 0 C to about 300 0 C.
- the gas may be syngas including carbon monoxide and hydrogen.
- the method may include recovering the catalyst on a support after the hydrogenation step.
- the catalyst may be attached to the support.
- the recovered catalyst on a support is reused in hydroformylation and hydrogenation reactions.
- the catalyst may be recovered by filtration.
- a method of making a polyol including hydroformylating an oil to form an aldehydic intermediate using a catalyst, and hydrogenating the aldehydic intermediate to form a polyol using the same catalyst in the presence of a support.
- the catalyst and the support may be added prior to hydroformylation.
- the catalyst may be added prior to hydroformylation, and the support may be added prior to hydrogenation.
- Some embodiments also include recovering the catalyst and support following hydrogenation for use in hydroformylation.
- polyol refers to a molecule having an average of greater than 1.0 hydroxyl groups per molecule. It may also include other functionalities.
- modified vegetable oil-based polyol refers to a non- naturally occurring polyol prepared by treating a vegetable oil so as to modify the chemical structure of the vegetable oil, thereby yielding the polyol.
- partially epoxidized vegetable oil refers to a non- naturally occurring oil prepared by treating a vegetable oil so as to modify the chemical structure of the molecule to epoxidize some but not all of the double bonds present in the vegetable oil.
- unsaturated modified vegetable oil-based polyols refers to vegetable oil-based polyols having residual double bonds.
- oligomeric modified vegetable oil-based polyol refers to a polyol that has at least two triglyceride-based monomer units present. It is also referred to as an "oligomeric polyol.”
- EOC epoxy oxygen content, which is the weight of epoxy oxygen per molecule, expressed in %.
- a partially epoxidized vegetable oil may be prepared by a method that includes reacting a vegetable oil with a peroxyacid under conditions that convert 5 less than 100% of the double bonds of the vegetable oil to epoxide groups. Typically, the method will also include combining another acid with the vegetable oil and peroxyacid components to form a mixture that reacts to form a partially epoxidized vegetable oil.
- the partially epoxidized vegetable oil may include at least about 10%, at least about 20%, at least about 25%, at least about o 30%, at least about 35%, at least about 40% or more of the original amount of double bonds present in the vegetable oil.
- the partially epoxidized vegetable oil may include up to about 90%, up to about 80%, up to about 75%, up to about 70%, up to about 65%, up to about 60%, or fewer of the original amount of double bonds present in the vegetable oil.
- One component of the reaction mixture is a vegetable oil.
- suitable vegetable oils include soybean oil, safflower oil, linseed oil, corn oil, sunflower oil, olive oil, canola oil, sesame oil, cottonseed oil, palm oil, rapeseed oil, rung oil, fish oil, peanut oil, and combinations thereof.
- Natural vegetable oils may be used, and also useful are partially hydrogenated vegetable oils and 0 genetically modified vegetable oils, including high oleic safflower oil, high oleic soybean oil, high oleic peanut oil, high oleic sunflower oil, and high erucic rapeseed oil (crambe oil).
- the number of double bonds present in a vegetable oil may be measured, and iodine value (IV) is a measure of the number of double bonds per molecule.
- One double bond per molecule roughly corresponds to an 5 iodine value of 28.
- commercially available soybean oil typically has around 4.6 double bonds/molecule, and typically has an iodine value of 127- 140.
- Canola oil typically has an iodine value around 115, corresponding to about 4.1 double bonds/molecule.
- the iodine values for the vegetable oils used will range from about 40 to about 240.
- oils having an 0 iodine value greater than about 80, greater than about 100, or greater than about 110 will be used.
- oils having an iodine value less than about 240, less than about 200, or less than about 180 will be used.
- Another component of the reaction mixture is a peroxyacid.
- peroxyacids examples include peroxyformic acid, peroxyacetic acid, trifluoroperoxyacetic acid, benzyloxyperoxyformic acid, 3,5- dinitroperoxybenzoic acid, m-chloroperoxybenzoic acid, and combinations thereof.
- peroxyformic acid or peroxyacetic acid will be used.
- the peroxyacids may be added directly to the reaction, or may be formed in-situ by reacting a hydroperoxide with a corresponding acid such as formic acid, benzoic acid, fatty acids such as oleic acid, or acetic acid.
- hydroperoxides examples include hydrogen peroxide, tert-butylhydroperoxide, tripheylsilylhydroperoxide, cumylhydroperoxide, and combinations thereof.
- the amount of acid used to form the peroxyacid is from about 0.25 to about 1.0 moles of acid per mole of double bonds in the vegetable oil, and more preferably from about 0.45 to about 0.55 moles of acid per mole of double bonds in the vegetable oil.
- the amount of hydroperoxide used to form the peroxy acid is 0.5 to 1.5 moles of hydroperoxide per mole of double bonds in the vegetable oil, and more preferably 0.8 to 1.2 moles of hydroperoxide per mole of double bonds in the vegetable oil.
- an additional acid component will also be present in the reaction mixture.
- suitable additional acids include sulfuric acid, toluenesulfonic acid, trifluoroacetic acid, fluoroboric acid, Lewis acids, acidic clays, or acidic ion exchange resins.
- a solvent may be added to the reaction.
- Suitable solvents include chemically inert solvents such as aprotic solvents.
- these solvents do not include a nucleophile, and are non-reactive with acids.
- Hydrophobic solvents such as aromatic and aliphatic hydrocarbons, are especially desirable.
- suitable solvents include benzene, toluene, xylene, hexane, pentane, heptane, and chlorinated solvents such as carbon tetrachloride.
- toluene will be used if a solvent is used in the reaction mixture.
- Solvents are useful in that they may be used to reduce the speed of the reaction or to reduce the number of side chain reactions.
- a solvent also acts as a viscosity reducer for the resulting composition.
- the reaction product may be neutralized.
- a neutralizing agent may be added to neutralize any remaining acidic components in the reaction product.
- Suitable neutralizing agents include weak bases, metal bicarbonates, or ion-exchange resins. Examples of neutralizing agents that may be used include ammonia, calcium carbonate, sodium bicarbonate, magnesium carbonate, amines, and resins, as well as aqueous solutions of neutralizing agents.
- the neutralizing agent will be an anionic ion-exchange resin.
- a suitable weakly-basic ion- exchange resin is Lewatit MP-64 ion-exchange resin (available from Bayer).
- a solid neutralizing agent such as an ion-exchange resin
- the oil may be filtered to remove the neutralizing agent after neutralization.
- the reaction mixture may be neutralized by passing the mixture through a neutralization bed containing a resin or other materials.
- the reaction product may be repeatedly washed to separate and remove the acidic components from the product.
- one or more of the processes may be combined in neutralizing the reaction product. For example, the product could be washed, neutralized with a resin material, and then filtered.
- excess solvents may be removed from the reaction product (partially epoxidized vegetable oil). These excess solvents may be solvents given off by the reaction, or those added to the reaction. The excess solvents may be removed by separation, vacuum, or other method. Preferably, the excess solvent removal will be accomplished by exposure to low vacuum.
- Vegetable oils of the type described herein typically are composed of triglycerides of fatty acids. These fatty acids may be either saturated, monounsaturated or polyunsaturated and contain varying chain lengths ranging from C 12 to C 24 .
- the most common fatty acids include saturated fatty acids such as lauric acid (dodecanoic acid), myristic acid (tetradecanoic acid), palmitic acid (hexadecanoic acid), steric acid (octadecanoic acid), arachidic acid (eicosanoic acid), and lignoceric acid (tetracosanoic acid); unsaturated acids include such fatty acids as palmitoleic (a Cl 6 acid), and oleic acid (a Cl 8 acid); polyunsaturated acids include such fatty acids as linoleic acid (a di-unsaturated Cl 8 acid), linolenic acid (a tri-unsaturated Cl 8 acid), and arachidonic acid (a
- the triglyceride oils are comprised of esters of these fatty acids in random placement onto the three sites of the trifunctional glycerine molecule.
- Different vegetable oils will have different ratios of these fatty acids and within a given vegetable oil there is a range of these acids as well depending on such factors as where the vegetable or crop is grown, maturity of the vegetable or crop, the weather during the growing season, etc. Because of this it is difficult to have a specific or unique structure for any given vegetable oil, but rather a structure is typically based on some statistical average.
- soybean oil contains a mixture of stearic acid, oleic acid, linoleic acid, and linolenic acid in the ratio of 15:24:50:11, this translates into an average molecular weight of approximately 800-860 daltons and an average number of double bonds of 4.4-4.7 per triglyceride.
- One method of quantifying the number of double bonds is the iodine value (IV) which is defined as the number of grams of iodine that will react with 100 grams of vegetable oil. Therefore for soybean oil, the average iodine value range from 120-140.
- Ra is independently selected from the fatty acid materials described above. Materials of this type are the starting materials for one embodiment of the present invention. In another embodiment these starting materials are converted by peroxyacids to fully or partially epoxidized vegetable oils.
- Ra is composed Of-(CO)Za”;
- Rb is composed of -(CO)Zb”;
- Rc is composed of -(CO)Zc".
- Unsaturated modified vegetable oil-based polyols may be prepared by combining a partially epoxidized vegetable oil with a ring opener and an acid.
- Suitable partially epoxidized vegetable oils may be prepared as described above.
- a ring opener will be used to open the epoxide rings in the partially epoxidized vegetable oil to form the unsaturated modified vegetable oil-based polyol.
- Various ring-openers may be used including proton donors such as alcohols and water (including residual amounts of water).
- an alcohol will be used.
- suitable alcohols that may be used in the reaction mixture forming the unsaturated modified vegetable oil-based polyols include methanol, ethanol, propanol, isopropanol, butanol, and mixtures thereof.
- methanol, ethanol, or a mixture thereof will be used. More preferably, methanol will be used.
- higher order alcohols may be used as ring openers, including polyols described elsewhere in this application.
- water may optionally be present in the reaction mixture.
- suitable acids for use in the reaction mixture include sulfuric acid and fluoroboric acid.
- fluoroboric acid will be used.
- the amount of acid used will preferably be at least 0.01%, at least 0.02%, or at least 0.05% by weight of the total reaction mixture.
- the amount of acid used will preferably be less than about 0.5%, less than about 0.3%, or less than about 0.2% by weight of the total reaction mixture.
- the reaction mixture may be heated as the components are added 5 together, or after the components have been combined.
- the reaction mixture will initially be heated to a temperature at least about 35 0 C, or at least about 50 0 C.
- the reaction mixture will be heated to a temperature less than about 12O 0 C, less than about 100 0 C, less than about 8O 0 C, or less than about 70 0 C.
- the reaction will proceed for an additional length of time.
- the reaction will proceed for a period of time ranging from 10 minutes to 12 hours or longer.
- the reaction will proceed for an additional 10 minutes or longer, 20 minutes or longer, or 30 minutes or longer.
- the reaction will proceed for an additional 5 hours 5 or less, 3 hours or less, 100 minutes or less, 75 minutes or less, 60 minutes or less, or 40 minutes or less.
- the temperature of the reaction mixture may reach a temperature about 4O 0 C or higher, or about 6O 0 C or higher.
- the reaction mixture may reach a temperature about 100 0 C or less, or about 80 0 C or less.
- the temperature of the reaction may be 0 controlled by a solvent or alcohol boiling point, or controlled from outside the reaction using a temperature control system, such as a water bath.
- the temperature of the reaction mixture may be reduced.
- the catalyst may be neutralized.
- a neutralizing 5 agent may be added to neutralize any remaining acidic components in the reaction product.
- Suitable examples of neutralizing agents include weak bases, metal bicarbonates, basic clays, or ion-exchange resins.
- suitable neutralizing agents include ammonia, calcium carbonate, calcium hydroxide, calcium oxide, hydrotalcite, ammonium carbonate, diethanolamine, 0 triethanolamine, sodium bicarbonate, magnesium carbonate, amines, alkali or alkaline earth hydroxides, and ion-exchange resins.
- the neutralizing agent may be prepared in a mixture before addition, such as in an aqueous slurry or aqueous solution.
- a basic ion-exchange resin will be used as the neutralizing agent.
- An example of a suitable ion-exchange resin is Lewatit MP-64 ion- exchange resin.
- the amount of neutralizing agent preferably is sufficient to ensure that essentially no free acid remains. If ammonium carbonate is used, the amount of ammonium carbonate preferably ranges from 0.05-1% by weight of the mixture, and more preferably from 0.1 -0.2% by weight. If a solid neutralizing agent, such as an ion-exchange resin, is used, the oil may be filtered to remove the neutralizing agent after neutralization. Alternatively, the reaction mixture may be neutralized by passing the mixture through a neutralization bed containing a resin or other materials.
- the reaction product may be repeatedly washed to separate and remove the acidic components from the product.
- one or more of the processes may be combined in neutralizing the reaction product, and more than one neutralizing agent may be used.
- the polyol product could be washed, neutralized with a resin material, and then filtered.
- remaining excess components other than the reaction product such as remaining ring opener components or components given off by the reaction, may be removed from the reaction product.
- These excess components may be removed by separation, vacuum, or other method.
- the excess components will be removed by exposure to low vacuum.
- the unsaturated modified vegetable oil-based polyols may have a range of desired characteristics depending upon various parameters including the components used, the reaction time, the reaction temperature, and the concentration of the ring opener.
- the unsaturated modified vegetable oil-based polyols will have a viscosity from about 0.05 Pa.s to about 12.0 Pa.s (at 25 0 C).
- the unsaturated modified vegetable oil-based polyols will have a viscosity from about 0.1 Pa.s to about 3.0 Pa.s, and more preferably to about 2.0 Pa.s (at 25°C).
- the viscosity of these polyols is low because the method avoids substantial side reactions such as polymerization and cross-linking.
- the unsaturated modified vegetable oil-based polyols will have a hydroxyl number from about 20 mg KOH/g to about 300 mg KOH/g .
- the unsaturated modified vegetable oil-based polyols will have a hydroxyl number at least about 50 mg KOH/g or higher, or at least about 75 mg KOH/g or higher.
- the unsaturated modified vegetable oil-based polyols will have a hydroxyl number about 200 mg KOH/g or lower, or about 180 mg KOH/g or lower.
- the unsaturated modified vegetable oil-based polyols will have an acid number from about 0.1 mg KOH/g to about 3.0 mg KOH/g. In general, the unsaturated modified vegetable oil-based polyols will have a number average functionality of about 0.5 or greater, or about 1.0 or greater. Typically, the unsaturated modified vegetable oil will have a number average functionality of less than about 10.0, or less than about 6.0 Generally, the unsaturated modified vegetable oil-based polyols will have a color value, using the Gardner color scale, of less than about 3.0. Preferably, the unsaturated modified vegetable oil-based polyols will have a Gardner color value of less than about 2.5.
- the Gardner Scale is a visual scale, and is described in ASTM D 1544, "Standard Test Method for Color of Transparent Liquids (Gardner Color Scale)” and ASTM D6166, “Standard Test Method for Color of Naval Stores and Related Products (Instrumental Determination of Gardner Color).”
- the Gardner scale ranges colors from light yellow to red defined by the chromaticities of glass standards numbered from 1 for the lightest to 18 for the darkest.
- the scale is used for chemicals and oils including resins, varnishes, lacquers, drying oils, fatty acids, lecithins, sunflower oil and linseed oil.
- the unsaturated modified vegetable oil-based polyols will have an iodine value in the range from about 5 g I 2 AOO g to about 150 g I 2 AOO g.
- the unsaturated modified vegetable oil-based polyols will have an iodine value of about 10 g I 2 / 100 g or higher, or about 30 g I 2 / 100 g or higher.
- the unsaturated modified vegetable oil-based polyols will have an iodine value of about 100 g I 2 AOO g or lower, or about 80 g I 2 AOO g or lower.
- Ra', Rb', and Rc' are independently derived from the partially epoxidized vegetable triglyceride oils materials described above. Materials of this type are the starting materials for one embodiment of the present invention. In another embodiment these starting materials are converted by peroxy acids to partially epoxidized vegetable oils.
- Ra' is composed of -(CO)Za';
- Rb' is composed of -(CO)Zb';
- Rc' is composed of -(CO)Zc'.
- Za', Zb', Zc' are independently comprise Cl 5 to C17 linear carbon chains. These linear carbon chains are comprised methylene units, vicinal hydroxymethylenealkoxymethylene units, 2,3-oxiranyl units, 1,2-ethenediyl units, or combinations thereof, and further comprising an endcap methyl group.
- R comprises H, Ci-C 10 alkyl groups, C 7 -Ci 5 alkaryl, alkoxyalkyl, or alkylaminoalkyl groups and combinations thereof.
- O and vicinal hydroxymethylenealkoxymethylene is defined as -CH(OH)-
- an unsaturated modified vegetable-oil based polyol will include at least one 1,2-ethenediyl unit.
- the total number of 2,3-oxiranyl units and vicinal hydroxymethylenealkoxymethylene units and 1 ,2-ethenediyl units will generally be approximately equal to the original number of double bonds found 5 in the starting vegetable oil prior to epoxidation and ring opening.
- Oligomeric modified vegetable oil-based polyols may be prepared from a o reaction mixture including an epoxidized vegetable oil, a ring opener, and acid.
- the first component is an epoxidized vegetable oil.
- the epoxidized vegetable oil may be fully epoxidized or partially epoxidized. Both saturated and unsaturated epoxidized vegetable oils can be used. Using saturated epoxidized vegetable oils having residual epoxy groups leads to oligomeric 5 polyols having good oxidative stability. It is also believed that the use of unsaturated epoxidized vegetable oils creates oligomeric polyols having a lower viscosity compared to products prepared using saturated epoxidized vegetable oils.
- the solvent will be removed before use in an oligomerization reaction. Generally, excess reactants from any preliminary reactions are also removed prior to the oligomerization reaction.
- the second component of the reaction mixture is an acid.
- the preferred acid catalyst is fluoroboric acid.
- the acid will preferably be present in an 5 amount from about 0.01 to about 0.3% by weight, based upon the total weight of the reaction mixture, and more preferably is present in an amount from about 0.05 to about 0.15% by weight.
- the third component is a ring opener, which acts as a proton donor.
- ring-openers may be used including alcohols, water (including residual 0 amounts of water), and other compounds having one or more nucleophilic groups. Combinations of ring-openers may be used.
- an alcohol will be used.
- suitable alcohols include methanol, ethanol, propanol, isopropanol, butanol, polyols, and vegetable oil-based polyols.
- Suitable vegetable-oil based polyols include hydroformylated vegetable oil based polyols, partially epoxidized vegetable oil-based polyols, and unsaturated modified vegetable oil-based polyols.
- the ring opener might be reduced hydroformylated compounds.
- Suitable reduced hydroformylated compounds include derivatives of reduced hydroformylated fatty acids.
- suitable derivatives of reduced hydroformylated fatty acids include esters, amides, and salts, such as reduced hydroformylated methyl esters of fatty acids.
- the ring opener could be trace amounts of water present in a reaction mixture. Under some conditions, the acid present in the reaction mixture might act as a ring opener. If an alcohol is used as a ring opener, preferably the ratio of the moles of hydroxyl groups to moles of epoxide groups present range from 0.1 to 1.0. More preferably the ratio will range from 0.3 to 0.6 moles hydroxyl groups to moles epoxide groups.
- a solvent may be added to the reaction mixture.
- Any aprotic solvent such as toluene, benzene, xylene, hexane, heptane, or chlorinated solvent would serve as a suitable solvent.
- a solvent acts as a viscosity reducer for the resulting composition.
- water may also be present in addition to any other ring- opener. If present, the amount of water may be greater than about 0.1% by weight based upon the total weight of the reaction mixture, greater than about 1% by weight, greater than about 5% by weight, or greater than about 10% by weight. If present, the amount of water may be less than about 25% by weight, less than about 20% by weight, or less than about 15% by weight.
- the ratio of the modified vegetable oil-based polyol to the epoxidized vegetable oil affects the molecular weight of the resulting oligomeric polyol. If both are used, preferably the ratio of the moles of hydroxyl groups to moles of epoxide groups present range from 0.2 to 1.0, and more preferably range from 0.25 to 0.5 moles hydroxyl groups to moles epoxide groups.
- the reaction may proceed for a period of time of at least 10 minutes. Typically, the reaction will proceed for a period of time from about 30 minutes to about 10 hours. Preferably, the reaction time will be from about 1 hour to about 3 hours. Typically, the reaction will be conducted at a temperature from about 25°C to about 100 0 C. Preferably, the temperature of the reaction will be from about 50°C to about 100 0 C. In general, it has been observed that the reaction proceeds quickly at a temperature in the range between 50 and 100 0 C. Less ring opener may be used when the reaction is carried out at a higher temperature. However, using a lower amount of ring opener may lead to a vegetable oil-based oligomerized polyol having a lower acid number than one made using a higher ring opener concentration in the reaction mixture.
- the unsaturated modified vegetable oil-based polyols may have a range of desired characteristics depending upon various parameters including the components used, the reaction time, the reaction temperature, and the concentration of the ring opener.
- the resulting oligomeric modified vegetable oil-based polyols may typically have a number average molecular weight greater than about 1200.
- the polyols will have a number average molecular weight greater than about 1500 or greater than about 2000.
- the polyols will have a number average molecular weight less than about 5000.
- the resulting oligomeric modified vegetable oil-based polyols will have a weight average molecular weight ranging from about 2000 to about 50,000. In general, the weight average molecular weight will be about 2 to about 10 times greater than the number average molecular weight.
- the viscosity of the oligomeric polyols changed to some degree according to oligomer content.
- the resulting oligomeric polyol will also have a hydroxyl equivalent weight from about 500 to about 2000.
- the resulting oligomeric polyols will have a hydroxyl number from about 20 mg KOH/g to about 300 mg KOH/g .
- the oligomeric polyol will have a hydroxyl number at least about 50 mg KOH/g or higher, or at least about 75 mg KOH/g or higher.
- the oligomeric polyol will have a hydroxyl number about 200 mg KOH/g or lower, or about 180 mg KOH/g or lower.
- the oligomeric polyol will have a functionality from about 0.5 to about 10.
- the functionality of the oligomeric polyol will be greater than about 1.0, greater than about 1.5, or greater than about 2.0.
- the functionality of the oligomeric polyol may be up to 6.0, up to 5.0, or up to 3.0.
- the preparation of vegetable oil-based oligomerized polyols using a hydroxyl ring opener with a partially epoxidized soybean oil has several advantages.
- the preparation of partially epoxidized soybean oil requires less epoxidation agents and requires shorter reaction time than the preparation of fully epoxidized oils.
- the resulting polyols made from partially epoxidized vegetable oils have a number of double bonds that may contribute to low viscosity.
- a further possible advantage is that oligomerization can be carried out in a controlled manner that may result in polyols of low molecular weight distribution.
- Another possible advantage is that the resulting oligomerized polyol may have low viscosity.
- Oligomeric content may be strongly affected by the catalyst concentration. It has been found that a higher catalyst concentration contributes to the formation of oligomer species of higher weight average molecular weight than 8000. However, at certain catalyst concentrations (such as greater than 0.3%), the reaction conditions result in a gelling of the reactants within less than 20 minutes of reaction time at 100 0 C.
- fluoroboric acid as the acid in the reaction mixture may be advantageous for several reasons. It is believed that at least some amount of the fluoroboric acid added to the reaction mixture deactivates, is consumed, or is incorporated in the reaction mixture over time. This is referred to as self- regulating behavior. When small quantities of fluoroboric acid is used, all of the acid catalyst may self-regulate, and it is not necessary to remove the catalyst from the reaction mixture. In addition, the neutralization step following the oligomerization reaction may not be necessary. Additionally, acid numbers of the resulting oligomeric polyol may be the same with or without the acid being removed following the reaction. The possibility of corrosion problems on the reaction equipment or on downstream equipment may be reduced. Self- regulation may also lead to greater control over the reaction conditions, and might be used to control the resulting oligomer profile of the resulting oligomeric modified vegetable oil-based polyols.
- Za, Zb, and Zc are each independently selected from the group consisting of
- R comprises H, Ci-Cio alkyl groups, C 7 -Ci 5 alkaryl, alkoxyalkyl, or alkylaminoalkyl groups and combinations thereof.
- a reduced hydroformylated vegetable oil-based polyol may be prepared by adding a vegetable oil and a catalyst to a reactor system, and subjecting the contents to a hydroformylation process.
- Polyols made by hydroformylation processes may be used in making oligomeric polyols as described above.
- These reduced hydroformylated polyols may include reduced hydroformylated polyols made by typical hydroformylation processes, or by a new hydroformylation process described herein. This new hydroformylation process provides advantages over conventional hydroformylation processes and is another aspect of the present invention.
- Vegetable oil-based polyols may be produced continuously from vegetable oil using a single metal in supported form as the catalyst for both the hydroformylation step and the hydrogenation steps of creating the polyol. After the hydrogenation step, this metal catalyst may be recovered by a simple filtration process and then reused in subsequent reactions.
- a catalyst that is f ⁇ nely- dispersed on a support and is in an organic media is charged into a first reactor 1.
- the contents of first reactor 1 are agitated under high pressures of syngas and high temperatures for a specific period of time.
- the contents are then transferred to a second reactor 2 where they are agitated with a specific amount of vegetable oil under high pressures of syngas and high temperatures for a specific period of time.
- the contents of second reactor 2 are then transferred to a third reactor 3 where they are agitated under certain pressures of hydrogen gas and certain temperatures for a specific period of time.
- the contents of third reactor 3 undergo filtration in a tower 4, and a catalyst on a support is collected.
- FIG. 1 A first figure.
- the catalyst may be finely dispersed on a solid support.
- the solid support may be a fine powder.
- the catalyst also may be a fine powder form.
- the catalyst may be mixed with the solid support or may be adsorbed or coated onto the surfaces of the support. Alternatively, a combination of the two methods described above of placing the catalyst on the solid support may be used.
- Catalysts suitable for this process include any of the transition metals within Group VIIIB of the periodic chart, i.e., Fe, Ru, Os, Co, Rh, Ir, Ni, Pd, and Pt. Combinations of transitional metals may be used. Preferably, Co and/or Rh is used, and most preferably, Co is used.
- Suitable solid supports may include inorganic compounds. Particularly useful supports include materials such as carbon black, alumina, silica, TiO 2 , MgO, ZnO, CaCO 3 , CaSO 4 , MgSO 4 , or combinations thereof. Preferably, the solid support is carbon black, alumina and/or silica, and more preferably is carbon black.
- the solid supports can be used in either inactivated or activated form. Preferably, they are used in an activated form.
- the metal-to-support ratio can vary widely.
- the metal to support ratio is about 0.1-10 by weight, more preferably about 0.1-2, and most preferably about 0.1-1.
- reactor 1 The contents of reactor 1 are agitated under high pressures of syngas and high temperatures to activate the metal. More specifically, this procedure converts the metal into metal carbonyls, which are precursors of the hydroformylation catalysts. Once the metal carbonyls are formed, they are removed from the surfaces due to the extracting effect of the organic media, and thus more metal carbonyls are formed.
- the activation of the catalyst is accomplished under higher pressures of syngas and high temperatures for a specific period of time.
- the ratio of carbon monoxide to hydrogen in the syngas is preferably in the range of about 0.5 - 2, and more preferably about 1.
- the pressure of the syngas mixture ranges from about 1000-5000 psig, preferably about 3000-4000 psig.
- a suitable temperature for the activation ranges from about 100-300 0 C and preferably about 150-200 0 C.
- the activation takes place in about 1 to 24 hours and preferably in about 1-8 hours.
- the organic media solubilizes the metal carbonyls formed, and preferably will not solubilize or disintegrate the solid support.
- the mixture thus remains as a slurry during the entire catalyst activation procedure.
- the organic media shall be compatible with the vegetable oil, the aldehydic intermediate, and the final polyol product.
- the organic media preferably has a much lower boiling point than the vegetable oil so that it can be recycled readily using vacuum stripping in tower 5.
- Suitable organic media include liquid organic compounds.
- Preferred organic media includes hexanes, heptanes, benzene, toluene, acetone, chloroform, methanol, ethanol, isopropanol, butanol, ethyl acetate, and combinations thereof.
- the organic media is selected from aromatics and/or hydrocarbons, such as toluene and hexanes.
- the hydroformylation is accomplished under a pressure of syngas of about 1000-5000 psig, preferably about 3000-4000 psig, and at a temperature of about 90-200°C and preferably about 100-15O 0 C.
- the molar ratio of carbon monoxide to hydrogen in the syngas is preferably in the range of about 0.5-2 and more preferably about 1.
- the reaction time for the conversion to aldehydic intermediates should be about 0.5 to 24 hours and preferably about 1-5 hours.
- Vegetable and petroleum based oils may be used.
- the crude product which contains the aldehydic oil, the organic media, the metal carbonyl catalyst solubilized within, and the solid support dispersed within as a slurry, is transferred directly to reactor 3 where the aldehydic intermediate is hydrogenated in order to produce a polyol. No catalyst/product separation and purification is necessary in this process in contrast to conventional hydroformylation processes.
- the hydrogenation of the aldehydic oil is accomplished by agitating the crude hydroformylation product in reactor 3 under certain pressures of hydrogen gas and certain temperatures for a specific period of time.
- the hydrogen pressure is about 500-2500 psig and preferably about 1000-2000 psig.
- the hydrogenation reaction temperature is about 120-200 0 C and preferably about 150-180 0 C.
- the hydrogenation reaction takes place for about 1-5 hours and preferably about 1-3 hours.
- the crude product is transferred to tower 4 where it is filtered.
- the crude product is a slurry of a polyol, organic media, and the catalyst in its metallic form mixed with or coated onto the solid support.
- the filtration procedure produces two components: a solid component, i.e., the precipitate, containing the catalyst and the support, and a liquid component, i.e., the filtrate, containing the polyol mixed with the organic media.
- a solid component i.e., the precipitate
- a liquid component i.e., the filtrate
- Other catalyst/product separation techniques such as extraction may be used.
- filtration is preferred.
- the liquid component containing the polyol and the organic media is subsequently transferred to tower 5 where it undergoes vacuum stripping to separate the polyol from the organic media.
- the organic media recovered from the stripping process may be recycled by feeding it back into reactor 1.
- the recovered catalyst-on-support and the collected organic media can be fed back to reactor 1 separately. It is, however, preferable to mix them together and send them back to reactor 1 in a slurry form so as to avoid any clogging.
- the cycle described above can be repeated many times to continuously produce vegetable oil-based polyols are produced continuously from vegetable oils.
- the hydroformylation process is more efficient and less costly than conventional hydroformylation processes because it can be accomplished in a shorter amount of time, with less energy, and catalyst/product separation steps and purification steps can be avoided. Further, the polyols produced by the process have less hydroxyl content loss than those formed by conventional processes because the catalyst is active at lower temperatures than 18O 0 C. When the process is performed at temperatures below 180 0 C, there is substantially no hydroxyl content loss.
- Another advantage of the hydroformylation process of the present invention is that the same metal catalyst may be used as the catalyst for the two consecutive steps of the process, i.e., the hydroformylation step and the hydrogenation step.
- a polyol can be produced directly and continuously by this hydroformylation process of the present invention.
- fewer steps are required.
- no corrosive reagents will be used in the hydroformylation process of the present invention.
- a high-pressure post-hydroformylation operation may not be necessary.
- Still another advantage of the hydroformylation process of the present invention is that the metal catalyst may be recycled simply by filtration and then the catalyst may be reused in a subsequent reaction.
- catalyst system of the present invention catalyst deposition on reactor walls or mirror formation is avoided.
- waste discharge problems associated with complicated catalyst/product separation and purification steps of conventional processes are avoided, which saves energy. Thus, there is little to no waste discharge. Thus, this process is better to the environment than conventional processes
- the polyols created by this hydroformylation method may be very reactive. Further, when these polyols are used in making coatings, they generally provide a UV resistant backbone for better weathering of coated substrates. Further, these polyols can usually be used as one-component moisture curing adhesives that have very good storage stability.
- Another method of making a polyol includes hydroformylating an oil to form an aldehydic intermediate using a catalyst and hydrogenating the aldehydic intermediate to form a polyol using the same catalyst in the presence of a catalyst support.
- the method may include recovering the catalyst and support following hydrogenation.
- the recovered catalyst and support may be re-used in hydroformylation and hydrogenation reactions.
- Suitable oils include vegetable- based oils as well as petroleum-based oils.
- Suitable catalysts include those described above. This method has the advantages of being able to be used with a wide range of feedstock oils, including blends. In addition, as the same catalyst is used in multiple reactions, the cost of separating or removing catalyst is minimized or eliminated.
- the cost of catalyst may be applied over a larger amount of materials produced.
- the catalyst is added prior to the hydroformylation reaction.
- the catalyst support may be added to the hydroformylation reaction, or it may be later added prior to the hydrogenation reactions. Preferably, the support will be added together with the catalyst prior to the hydroformylation reaction.
- the catalyst in the presence of the support, may attach to the support.
- At least about 50% of the catalyst present will attach to the catalyst support, at least about 75% of the catalyst present will attach to the support, at least about 90% of the catalyst present will attach to the support, at least about 95% of the catalyst present will attach to the support, at least about 99% of the catalyst will attach to the support, or at least 99.9% of the catalyst present will attach to the support.
- Examples of a variety of partially epoxidized vegetable oils, hydroformylated polyols, unsaturated modified vegetable oil-based polyols, and oligomeric polyols are described below.
- a partially epoxidized soybean oil was prepared as follows: A 5 liter, 3-neck, round bottom flask was equipped with temperature control, an addition funnel, reflux condenser and stirring. To this reactor system was added: 1500 grams of soybean oil (RBD grade having an Iodine Value of 131 g I 2 / 100 g and a viscosity of 62 mPa s, available from Archer Daniels
- the contents of the reactor system were transferred to a 3 liter separatory funnel and allowed to cool down. During the cool down period, the water and crude partially epoxidized soybean oil separated into two layers. Product work-up continued by draining off this first water layer and then water washing the crude partially epoxidized soybean oil layer three separate times with 1 liter aliquots of distilled water. The washed partially epoxidized soybean oil was then isolated again and added to an Erlenmeyer flask, and 100 grams of a basic ion exchange resin (Lewatit MP-64 from Bayer) was added. This mixture was stirred for 2 hours to allow neutralization of any remaining acid.
- a basic ion exchange resin Lewatit MP-64 from Bayer
- a series of partially epoxidized soybean oils were prepared according to Example 1, except the time of the reaction and amounts of reactants were changed.
- the amounts of reactants used and the time reacted are listed in Table 1 on the rows EX2, EX3, EX4, and EX5 for these examples.
- the final partially epoxidized soybean oil products obtained had the characteristics as shown in Table 1 on the same rows.
- a series of partially epoxidized soybean oils were prepared according to Example 1, except the time of the reaction and amounts of reactants were changed.
- the hydrogen peroxide was added by a peristaltic pump at a rate of 7.5 ml/min, rather than by a dropping funnel over 30 minutes.
- a partially epoxidized soybean oil was prepared as follows: A 2 liter, 3-neck, round bottom flask was equipped with temperature control, an addition funnel, reflux condenser and stirring. To this reactor system was added 500 grams soybean oil (RBD grade having an Iodine Value of 127 g I 2 AOO g and a viscosity of 60 mPa s, available from Archer Daniels Midland Company); 75 grams of glacial acetic acid; and 6.36 grams of a 50% solution of sulfuric acid in water. The components were thoroughly mixed while the reactor system was brought up to a temperature of 70 0 C.
- a modified soybean oil-based polyol was prepared according to the procedure described in Example 6 of Petrovic, U.S. Patent Number 6,433,121. Typical features of the product included positive reactivity with isocyanate compounds, terminal hydroxyls that are secondary in nature, a hydroxyl functionality of 3.8, a hydroxyl number of 200 and a 25°C viscosity in the range of 12,000 mPa s. The product was a light straw in color and revealed a very mild and characteristic odor.
- a hydroformylated polyol was prepared as follows.
- a experimental setup of a 500 milliliter, stainless steel, high-pressure reactor equipped with temperature control and an addition port for gas and stirring was provided.
- 100 grams (0.512 moles of double bonds) of soybean oil commercially purchased from the Archer Daniels Midland Company as the RBD grade and having an Iodine Value of 127 g I 2 /100 g and a viscosity of 0.06 Pa s.
- Also added to the reactor were 5 grams of activated carbon (available from Aldrich) and 5 grams of cobalt carbonyl (available from Strem Chemicals).
- the reactor was closed up and these ingredients were thoroughly mixed while the reactor system was flushed four times with 50-100 psig of a synthetic gas mixture consisting of an equal molar ratio of hydrogen and carbon monoxide (available from Airgas, Tulsa, OK).
- the reactor was then pressurized to 3,200 psig with the same gas composition and heated while stirring to 120 0 C, by which time the pressure of the reactor had increased to 4,000 psig. Stirring continued at 1,000 rpm for 1 hour, after which the pressure was released.
- the reactor was then flushed four times with 50-100 psig of hydrogen gas (available from Airgas, Tulsa, OK), pressurized to 1,800 psig of hydrogen, and the heated to 175 0 C, by which time the pressure of the reactor had increased to 2,000 psig.
- the contents of the reactor were stirred at 1,000 rpm for 2 hours under 2,000 psig of hydrogen at 175 0 C.
- the reactor was opened up and the contents were transferred out and filtered through a fritted glass funnel.
- the black powder collected in the funnel weighed approximately 13 grams while wet, and the yellow viscous liquid filtrate weighted approximately 110 grams.
- the polyol had 147 mg KOH/g and a 25 0 C viscosity of about 4,000 cps at 25 0 C.
- a hydroformylated polyol was prepared as follows:
- a 500-ml, stainless steel, high-pressure reactor was setup with temperature control, stirring, and addition ports for gas and stirring.
- 100 grams of soybean oil having an Iodine Value of 127 g I 2 / 100 grams and a viscosity of 60 mPa. s (RBD grade, available from the Archer Daniels Midland Company) was added to the reactor.
- 0.129 grams of rhodiumdicarbonyl acetylacetonate (available from Johnson Mathey Co.), and 0.66 grams of triphenyl phosphine (available from Aldrich) were added to the reactor.
- the reactor was closed up and the ingredients were thoroughly mixed while the reactor system was flushed with three volumes of a synthetic gas mixture consisting of an equal molar ratio of hydrogen and carbon monoxide.
- the reactor was then pressurized to 13.4 MPa using the same gas composition.
- the reactor system was heated to increase the temperature to 90 0 C over a period of 25 minutes while continuing the mix the ingredients. After 2 hours at 90 0 C, the temperature of the reactor was decreased to 70 0 C.
- the reactor was then flushed with three volumes of hydrogen gas.
- the reactor was then sealed and pressurized to 3.4 MPa using hydrogen gas. Using heat and continuing to mix the contents, the reactor content temperature was increased to 130 0 C. After 30 minutes at 130 0 C, the reactor was cooled. When the contents of the reactor reached 30 0 C, the pressure was released, and the reactor opened.
- the reactor was then cooled to room temperature, and the gas pressure released.
- the reactor contents were then filtered through Celite (available from Fisher Scientific) and then subject to vacuum filtration to remove residual solvent.
- the final recovered modified soybean oil-based polyol was a light brown liquid having a hydroxyl number of 2200 mg KOH/g and a viscosity of 14,000 mPa.s at 25 0 C.
- Example 15 Polyol preparation began with the experimental setup of a 1 liter, 3 -neck, round bottom flask equipped with temperature control, an addition funnel, reflux condenser and stirring. To this reactor system was added 80 grams of methanol and 0.7 grams of fluoroboric acid (as a 48% mixture with water, available from Aldrich). These ingredients were thoroughly mixed while the reactor system was brought to boiling. Then 250 grams of the partially epoxidized soybean oil prepared according to Example 2 was quickly added to the vigorously stirred reactor.
- a 1 liter Erlenmeyer flask was equipped with temperature control, an addition funnel, reflux condenser and stirring. 250 grams of a polyol prepared according to Example 15 and 2.5 grams of ammonium carbonate were added to the flask. The ingredients were thoroughly mixed while the reactor system was brought to 60-70 0 C.
- the final recovered unsaturated modified soybean oil-based polyol had the properties as shown in Table 3.
- An oligomeric polyol was prepared as follows: A 1 liter, 3 -neck, round bottom flask was equipped with temperature control, an addition funnel, reflux condenser and stirring. To the reactor was added 63 grams of a polyol prepared according to Example 13 and 0.5 grams of fluoroboric acid (as a 48% mixture with water, available from Aldrich). These ingredients were thoroughly mixed while the reactor system was brought to 100 0 C. Then 150 grams of a partially epoxidized soybean oil prepared according to Example 1 was quickly added to the vigorously stirred reactor.
- a 1 liter, 3 -neck, round bottom flask was equipped with temperature control, an addition funnel, reflux condenser, nitrogen purge, and stirring.
- To the reactor was added 50 grams of a polyol prepared according to Example 12, 0.1% BHT, and 0.5 grams of fluoroboric acid (as a 48% mixture with water, available from Aldrich). These ingredients were thoroughly mixed while the reactor system was brought to 100 0 C. Then, 200 grams of a partially epoxidized soybean oil prepared according to Example 2 was quickly added to the vigorously stirred reactor, and allowed to react for an additional 30 minutes.
- Example 21 An oligomeric polyol was prepared according to the procedure of
- Example 20 except using the amounts of reactants and time as listed in Table 4 for the row "EX21.”
- the resulting oligomeric polyol had the characteristics as shown in Table 5.
- This oligomeric polyol began with the experimental setup of a 2 liter, 3 -neck, round bottom flask equipped with temperature control (water bath), reflux condenser and mechanical stirrer. To this reactor system was added 35.5 grams of methanol (certified A.C. S., available from Fisher) and 1.12 grams of tetrafluoroboric acid (as a 48% water solution, available from Aldrich). These ingredients were thoroughly mixed while the reactor system was brought up to a temperature of 5O 0 C. After attaining the temperature set point, 400 grams of an epoxidized soybean oil ("Flexol," available from Union Carbide) was added to the reactor. Vigorous stirring continued and the reactor temperature was increased to 90 0 C.
- methanol certified A.C. S., available from Fisher
- tetrafluoroboric acid as a 48% water solution, available from Aldrich
- the final recovered oligomeric modified soybean oil-based polyol was a light straw in color and had the properties as shown in Table 7 for the row EX22.
- the polyol under GPC analysis showed the following composition: 47% monomer; 12% dimer; 8% trimer; and 33% tetramer & high oligomers.
- Example 23 An oligomeric polyol was prepared according to the following procedure:
- a reactor system was setup including a 2 liter, 3 -neck, round bottom flask equipped with temperature control (water bath), reflux condenser and mechanical stirrer. 26.8 g of methanol (0.838 mol) and 1.10 g of 48% water solution ofHBF 4 catalyst were added into the flask. Sufficient catalyst was added to obtain a catalyst concentration of 0.1 % of the total weight of the reactants. Sufficient methanol was added to obtain a molar ratio of methanol to epoxy of 0.4 to 1. The mixture was heated to 40 0 C and a first portion of 400 g of epoxidized soybean oil (1.675 mol of epoxy groups) was added to the flask (80% of the total amount to be added).
- reaction started very quickly and the temperature of the reaction mixture jumps up to 115°C, followed by very strong boiling for several seconds. Then, the temperature of reaction mixture decreased and the boiling intensity decreased. The temperature of the water bath was increased to 90 0 C and the reaction continued. After 30 minutes, lOOg (0.419 mol) of epoxidized soybean oil was added into the flask with the other components (this is the remaining 20% of the total to be add). After addition, the reaction continued.
- the final recovered oligomeric modified soybean oil-based polyol had the properties as shown in Table 7 for the row EX23.
- the polyol under GPC analysis showed the following composition: 48% monomer; 11 % dimer; 7 % trimer; 34 % tetramer & higher oligomers.
- the number-average molecular weight determined by vapor pressure osmometry (VPO) was 1678 g/mol and the functionality of the oligomeric polyol was 2.1.
- EX24 The final recovered oligomeric modified soybean oil-based polyol had the properties as shown in Table 7 for the row EX24.
- the polyol produced in EX24 under GPC analysis showed the following composition: 49% monomer; 11% dimer; 7% trimer; 33% tetramer & higher oligomers.
- VPO was 1755 g/mol and the functionality of the oligomeric polyol was 2.35.
- EX25 The final recovered oligomeric modified soybean oil-based polyol had the properties as shown in Table 7 for the row EX25. In addition, the polyol under GPC analysis showed the following composition: 41% monomer; 12% dimer; 8% trimer; 39% tetramer & higher oligomers.
- EX26 The final recovered oligomeric modified soybean oil-based polyol had the properties as shown in Table 7 for the row EX26.
- the polyol under GPC analysis showed the following composition: 56% monomer; 9% dimer; 6% trimer; 29% tetramer & higher oligomers.
- the number-average molecular weight determined by vapor pressure osmometry (VPO) was 1505 g/mol and the functionality of the oligomeric polyol was 1.95.
- oligomeric polyols were prepared according to the procedure as described in Example 23. However, in these examples, all of the epoxidized vegetable oil was added in the initial addition of epoxidized vegetable oil, and no second addition of epoxidized vegetable oil occurred. The differences in the conditions used are shown on Table 8, on the appropriate row, which shows the various processing parameters used.
- the final recovered oligomeric modified soybean oil-based polyols had the properties as shown in Table 9 for the appropriate row.
- a 1 liter, 3 -neck, round bottom flask was equipped with temperature control, an addition funnel, reflux condenser, nitrogen purge, and stirring.
- a polyol prepared according to Example 14 was added to the reactor.
- fluoroboric acid as a 48% mixture with water, available from Aldrich.
- 82.5 grams of a partially epoxidized soybean oil prepared according to Example 1 was quickly added to the vigorously stirred reactor, and allowed to react for an additional 60 minutes. After reacting, the system was cooled down to 50 0 C and 10 grams of a basic ion exchange resin (Lewatit MP-64 from Bayer) was added to neutralize acids.
- a basic ion exchange resin Lewatit MP-64 from Bayer
- a series of oligomeric polyols were prepared according to the procedure of Example 23, except using the amounts of reactants and time as listed in Table 10 for the rows EX46, EX47, EX48, and EX49.
- EX 46 sample the epoxidized vegetable oil was washed and dried prior to use in the reaction. The oil was washed using an equivalent volume of warm distilled water, and then dried by being placed in a flask with 10 grams of anhydrous sodium sulfate.
- EX47, EX48, and EX49 the epoxidized vegetable oil was washed using an equivalent volume of warm distilled water prior to addition to the reaction.
- the resulting oligomeric polyols had the characteristics as shown in Table 11.
- An oligomeric polyol was prepared according to the following: A 250-ml, 3-neck, round bottom flask was equipped with temperature control, an addition funnel, reflux condenser, nitrogen purge, and stirring. To the reactor was added 10 grams of a polyol prepared according to Example 12, 0 grams of water, and 0.05 grams of fluoroboric acid. These ingredients were thoroughly mixed while the reactor system was brought to 100 0 C.
- a series of oligomeric polyols were prepared according to the procedure of Example 50, except using the amounts of reactants and time as listed in Table 12 for the rows EX51, EX52, EX53, and EX54. A sample of EX51 was taken at 90 minutes.
- this oligomeric polyol began with the experimental setup of a 2 liter, 3 -neck, round bottom flask equipped with an addition funnel, reflux condenser and stirring. To this reactor system was added 100 grams of the polyol prepared according to Example 12. The flask was immersed in a boiling water bath. After a few minutes, 1.0 grams of fluoroboric acid (as a 48% mixture with water, available from Aldrich) was added to the flask and mixed. After several minutes of mixing, 400 grams of the polyol prepared according to Example 2 was added to the flask. After 30 mintues of reaction, 80 grams of methanol (certified ACSS grade, available from Aldrich) was added to the flask.
- fluoroboric acid as a 48% mixture with water, available from Aldrich
- An oligomeric polyol was prepared according to the procedure of Example 55, except using the amounts of reactants as listed in Table 14 for the row EX56.
- the final recovered oligomeric polyol had the properties as shown in Table 15 for the row "EX56.”
- the polyol under GPC analysis exhibited the composition profile as shown in Table 16, under the column EX56.
- this oligomeric polyol began with the experimental setup of a 1 liter, 3 -neck, round bottom flask equipped with an addition funnel, reflux condenser, nitrogen inlet, and stirring. To this reactor system was added 60 grams of the polyol prepared according to Example 12 and 0.3 grams of BHT antioxidant (2,6-Di-tert-butyl-4-methylphenol, available from Aldrich). The flask was immersed in a boiling water bath. The reaction mixture was constantly maintained under a nitrogen atmosphere throughout the reaction.
- BHT antioxidant 2,6-Di-tert-butyl-4-methylphenol
- the final recovered oligomeric polyol had the properties as shown in Table 15 for the row EX57.
- the polyol under GPC analysis exhibited the composition profile as shown in Table 16, under the column EX57.
- An oligomeric polyol was prepared according to the following: A 250-ml, 3-neck, round bottom flask was equipped with temperature control, an addition funnel, reflux condenser, and stirring. 60 grams of an epoxidized soy oil prepared according to Example 6, 0.72 grams of methanol (ACS grade, available from Aldrich), and 0.12 grams of fluoroboric acid were added to the reactor. These ingredients were thoroughly and continually mixed as the reactor was placed into a water bath and brought to 60 0 C.
- the oligomeric polyol formed had the properties as shown in Table 18, with properties reported for the sample at 180 minutes, and the final polyol composition.
- An oligomeric polyol was prepared according to the procedure of Example 58, except using the amounts of reactants and temperature as listed in Table 17 for the row EX59.
- the oligomeric polyol had the properties as shown in Table 18 for samples at 180 minutes, and a final sample.
- Example 60 An oligomeric polyol was prepared according to the procedure of
- Example 58 except using the amounts of reactants and temperature as listed in Table 17 for the row EX60, and the experiment was discontinued after 60 minutes of reaction time, at which time a sample was taken. The later steps of Example 58 were not completed.
- the oligomeric polyol had the properties as shown in Table 18, with the time at which the sample was taken. TABLE 17. Oligomeric Polyol Formulations - Temp, and Catalyst Concentration Variation
- An oligomeric polyol was prepared according to the procedure of Example 58, except using the amounts of reactants and temperature as listed in Table 17 for the row EX61. The experiment was discontinued after 60 minutes of reaction time, at which time a sample was taken. The oligomeric polyol had the properties as shown in Table 18, with the time at which the sample was taken.
- oligomeric polyol was prepared according to the procedure of Example 58, except using the amounts of reactants as listed in Table 17 for the row EX62. The experiment was discontinued after 120 minutes of reaction time, at which time a sample was taken. The oligomeric polyol had the properties as shown in Table 18, with the time at which the sample was taken. TABLE 18. Oligomeric Polyol Properties - Temp, and Catalyst Concentration Variation
- An oligomeric polyol was prepared according to the procedure of Example 58, except using the amounts of reactants as listed in Table 17 for the row EX63. In addition, a jacketed flask was used for temperature control, rather than a water bath, and the temperature jumped to 82 0 C at the beginning of the reaction, and was then brought back down to 60 0 C. The experiment was discontinued after 120 minutes of reaction time, at which time a sample was taken. The oligomeric polyol had the properties as shown in Table 18, along with the time at which the sample was taken.
- An oligomeric polyol was prepared according to the procedure of Example 58, except using the amounts of reactants as listed in Table 17 for the row EX64. A water bath was used, and the temperature jumped to 65 0 C at the beginning of the reaction, and was then brought back down to 6O 0 C. The experiment was discontinued after 120 minutes of reaction time, at which time a sample was taken.
- the oligomeric polyol had the properties as shown in Table 18, along with the time at which the sample was taken.
- An oligomeric polyol was prepared according to the procedure of Example 58, except using the amounts of reactants as listed in Table 19 for the row EX65.
- the oligomeric polyol had the properties as shown in Table 20, along with the time at which the sample was taken. The last sample was taken at 75 minutes.
- An oligomeric polyol was prepared according to the procedure of Example 58, except using the amounts of reactants as listed in Table 19 for the row EX66.
- the oligomeric polyol had the properties as shown in Table 20, along with the time at which the sample was taken. The last sample was taken at 90 minutes.
- An oligomeric polyol was prepared according to the procedure of Example 58, except using the amounts of reactants as listed in Table 19 for the row EX67. As shown, MEK (available from Aldrich) was added to the reaction rather than methanol. The oligomeric polyol had the properties as shown in Table 21, along with the time at which the sample was taken. The last sample was taken at 160 minutes.
- An unsaturated oligomeric polyol was prepared according to the following:
- a 1-L, three-neck round bottom jacketed reaction flask was equipped with a thermometer, addition funnel, reflux condenser, temperature control, and a mechanical stirrer.
- a series of unsaturated oligomeric polyols were prepared according to the procedure of example 68, except using the reactants, amounts, and conditions as shown on Table 22.
- the unsaturated oligomeric polyols formed had the properties as shown in Table 23 and Table 24.
- Example 13 The black powder (approx 13 grams) collected in Example 13 was returned into the 500-mL pressure reactor. 50 mL of toluene (Fisher Scientific, Pittsburgh, PA) was added to the reactor, and the reactor sealed. The interior was flushed 4 times with 50-100 psig of syngas (1:1 CO/H 2 ). Afterwards, the reactor was pressurized to 2,700 psig with syngas and heated to 180 0 C while stirring. At this time, the pressure of the reactor had reached 4,000 psig. The contents of the reactor were stirred at 1,000 rpm for 5 hours under 4,000 psig of syngas at 180 0 C.
- the reactor was then flushed 4 times with 50-100 psig of hydrogen gas, pressurized to 1,800 psig of hydrogen, and heated to 175 0 C, by which time the pressure of the reactor had reached 2,000 psig.
- the contents of the reactor were stirred at 1,000 rpm for 2 hours under 2,000 psig of hydrogen at 175°C.
- the pressure of the reactor was released, and the contents were transferred out and filtered through a fritted-glass funnel.
- the black powder collected in the funnel weighed approx. 12 grams while wet, and the yellow viscous liquid filtrate weighed approx. 110 grams.
- the polyols present in the yellow viscous liquid had a hydroxyl content of 161 mg KOH/g (67% yield) and a viscosity of ca. 4,000 cps at 25°C.
- Example 77 The procedure described in Example 77 was followed using the catalyst recovered from Example 77.
- the polyol obtained had a hydroxyl content of 161 mg KOH/g (67% yield) and a viscosity of ca. 4,000 cps at 25°C.
- a black powder produced according to the method of Example 13 was placed back into the 500-mL pressure reactor, along with 50 mL of toluene.
- the reactor was sealed and the contents flushed 4 times with 50-100 psig of syngas.
- the reactor was pressurized to 2,700 psig of syngas and heated while stirring to 18O 0 C, by which time the pressure of the reactor had reached 4,000 psig.
- the contents of the reactor were stirred at 1,000 rpm for 5 hours under 4,000 psig of syngas at 180 0 C.
- the contents of the reactor were then cooled, under a syngas pressure of 3,500-4,000 psig, to room temperature, and the pressure was released. 100 grams of RBD grade soybean oil was added to the reactor.
- the reactor was sealed again and the contents flushed 4 times with 50- 100 psig of syngas. Afterwards, the reactor was pressurized to 3,200 psig of syngas and heated while stirring to 120 0 C, by which time the pressure of the reactor had reached 4,000 psig. The contents of the reactor were stirred at 1,000 rpm for 1.5-2 hours under 4,000 psig of syngas at 120 0 C. The contents of the reactor were then cooled to room temperature and the pressure was released.
- the crude product was filtered on a fritted-glass funnel, and an aldehydic oil was obtained along with some catalyst solubilized within.
- the Atomic Absorption analysis for cobalt of the filtrate showed that 54% of the original catalyst was present as the carbonyl form.
- Example 80 The procedure described in Example 13 was followed except the amount of carbon was 1 gram. The black powder collected weighed 3.5 grams while wet.
- Example 81 The procedure described in Example 79 was followed using the black powder recovered from Example 80. The Atomic Absorption analysis for cobalt of the filtrate showed that only 8% of the original catalyst was present as the carbonyl form.
- Example 13 The procedure described in Example 13 was followed except the amount of carbon was 10 grams. The black powder collected weighed 25.0 grams while wet.
- Example 79 The procedure described in Example 79 was followed using the black powder recovered from Example 82.
- the Atomic Absorption analysis for cobalt of the filtrate showed that 63% of the original catalyst was present as the carbonyl form.
- the reactor was then flushed 4 times with 50-100 psig of hydrogen gas, pressurized to 1,800 psig of hydrogen, and heated to 15O 0 C, by which time the pressure of the reactor had reached 2,000 psig.
- the contents of the reactor were stirred at 1,000 rpm for 3 hours under 2,000 psig of hydrogen at 150 0 C.
- the reactor contents were then cooled to 40-50 0 C and the pressure of the reactor was released.
- the contents were transferred out and filtered. FT-IR analysis of the viscous liquid filtrate showed that 24% of the aldehyde from hydroformylation was still present.
- the head space of the reactor represents the volume of the syngas available for the hydroformylation reaction to take place. Although more syngas is supplied during the reaction, this process is dispersion controlled (i.e., the dispersion of gases to the liquid is much slower than the reaction rate).
- the number average molecular weight of the polyol was 1135, the weight average molecular weight of the polyol was 1332, and the functionality was 2.34.
- a series of oligomeric polyols were prepared via a ring opening reaction performed in a three-necked round bottom glass reactor prepared with very strong stirring and a reflux condenser. Catalyst solution was carefully added into a hydroformylated polyol prepared according to the procedure of Example 13. The mixture was preheated to 60 0 C and strongly mixed. The temperature was raised to 90-95 0 C and an amount of an epoxidized soybean oil ("Flexol,” available from Union Carbide) was slowly added into the reactor. The mixture was then allowed to react for a specified time. The amount of reactants and reaction time is shown on Table 28.
- Lewatite MP 64 resin for 1 hour at 60 0 C, after which the reaction mixture was diluted with ether and the Lewatite resin was filtered off.
- the solvents were removed from the polyol using rotavapor (45 min at 70 0 C oilless pump and 90 minutes at 90 0 C high vacuum pump).
- the resulting polyols had the properties as shown in Table 29.
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Abstract
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EP05764268.8A EP1797057B1 (en) | 2004-06-25 | 2005-06-24 | Modified vegetable oil-based polyols |
MX2007000022A MX2007000022A (en) | 2004-06-25 | 2005-06-24 | Modified vegetable oil-based polyols. |
PL05764268T PL1797057T3 (en) | 2004-06-25 | 2005-06-24 | Modified vegetable oil-based polyols |
CA002571214A CA2571214A1 (en) | 2004-06-25 | 2005-06-24 | Modified vegetable oil-based polyols |
BRPI0512511-1A BRPI0512511A (en) | 2004-06-25 | 2005-06-24 | method of producing a polyol, oligomeric mixture of a modified fatty acid triglyceride, and polyol composition based on oligomeric vegetable oil |
JP2007518333A JP2008504287A (en) | 2004-06-25 | 2005-06-24 | Modified vegetable oil based polyols |
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EP1797057A1 (en) | 2007-06-20 |
US20060041157A1 (en) | 2006-02-23 |
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US20100311992A1 (en) | 2010-12-09 |
BRPI0512511A (en) | 2008-03-11 |
US7786239B2 (en) | 2010-08-31 |
JP2008504287A (en) | 2008-02-14 |
CA2571214A1 (en) | 2006-02-02 |
US8153746B2 (en) | 2012-04-10 |
PL1797057T3 (en) | 2019-02-28 |
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